Battery Connecting Pole Labyrinth Seal Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connecting poles for rechargeable batteries are complex and costly to manufacture, requiring laborious processes like die rolling to produce hook-like profiles, and do not effectively prevent acid leakage.
Innovation Solution
A connecting pole design featuring peripheral projections with undercuts that can be flanged in pairs using simpler tools, reducing manufacturing complexity and costs, and incorporating a tooth system for anti-rotation, which can be manufactured using extrusion presses or molding processes, forming a labyrinth seal with injection molding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If die rolling is used to produce hook-like profiles on peripheral projections, then the connecting pole can be manufactured with traditional methods, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent changes the manufacturing parameter from die rolling to flanging process. The peripheral projections are formed by flanging a blank material in such a way that the profiled shape with undercut is created directly during the flanging operation, eliminating the need for subsequent die rolling steps. This parameter change simplifies the manufacturing process while achieving the same functional result.
2Productivity
If peripheral projections are flanged in pairs toward each other, then manufacturing time is reduced, but the tooling requirements become more specific
Solution Approach 1:
The patent employs asymmetric flanging where adjacent peripheral projections are flanged in pairs toward each other in mutually opposite directions. This asymmetric arrangement allows the flanging forces to counterbalance each other, enabling the use of simpler flanging tools without complex thrust load management, while simultaneously reducing manufacturing time compared to sequential processing.
3Reliability
If traditional connecting pole designs are used, then the structure is simpler, but they fail to provide effective acid leakage prevention
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the undercut profile on the peripheral projections during the flanging process. This undercut structure is created in advance before the connecting pole is inserted into the housing, allowing the injection molding material to effectively lock into the undercut regions and form a reliable labyrinth seal that prevents acid leakage.
4Manufacturing precision
If flanging forces are applied to peripheral projections, then undercuts are formed for sealing, but thrust load must be managed
Solution Approach 1:
The patent applies the counterweight principle by arranging peripheral projections in pairs that are flanged toward each other in opposite directions. The flanging forces generated on adjacent projections act in opposite directions and substantially counterbalance each other, resulting in minimal net thrust load on the tooling system while still forming the required undercut profiles with high precision.
Data Source
AI summary
The invention relates to a connecting pole (1) for a rechargeable battery (12) having the following features: a) the connecting pole (1) has a connecting section (2), in which a pole terminal can be fastened on the connecting pole (1), b) the connecting pole (1) has a fastening section (3), in which the connecting pole (1) can be fastened in a housing part (5) of the rechargeable battery (12), c) the fastening section (3) has a labyrinth section (4), d) the outer wall (6) of the connecting pole (1) has, in the labyrinth section (4), one or more peripheral projections (7, 8, 10), e) at least two adjacently arranged peripheral projections (70, 71, 72, 73, 80, 81, 82, 83) are flanged in pairs in the mutually facing direction, wherein a recess (11) is formed on each of the peripheral projections (70, 71, 72, 73, 80, 81, 82, 83) with respect to the outer wall (6) of the connecting pole (1) by the flanged region. The invention also relates to a rechargeable battery housing or a part thereof with at least one such connecting pole and to a machine for producing such a connecting pole.